Modular Automation: How to Start Small & Scale Big in Your Warehouse
Modular automation helps warehouses start small, reduce risk, and scale efficiently over time without costly system overhauls or operational disruption.
Packaging and Shipping Automation: Choose a Partner, Not Just a Vendor
When you’re evaluating fulfillment automation solutions for eCommerce or pharmacy operations, it’s easy to focus on the machinery. Specs, cycle rates, integration points, and price all matter. They just don’t tell the whole story. The vendor behind the system will influence your uptime, your accuracy, and even how confidently your team can push through seasonal, clinical, or regulatory demands. Automation isn’t a one-and-done purchase. It’s a long-term relationship that should strengthen your operation’s daily performance.
Here’s what to look for when choosing a packaging and automation partner—and why those qualities matter.
1. Ongoing Service and Support
When something goes wrong in a fulfillment or pharmacy environment, you don’t have hours to spare. You need quick answers, trained technicians, and a service structure that gets you back online. A strong partner offers responsive troubleshooting, predictable maintenance plans, and technicians who know your system inside and out.
eCommerce Example: Picture your automated bagger stalling on Cyber Monday. Orders keep flowing, but your system isn’t. A partner with fast-response support and stocked replacement parts prevents a three-hour hiccup from becoming a three-day backlog. Their goal should be to treat installation as the starting line, not the finish line.
2. A Comprehensive Offering
Your automation equipment doesn’t operate in a vacuum. You need compatible machines, software, packaging materials, labeling systems, and often robotics or conveyance. A partner with solutions and experience across the full ecosystem can help you avoid patchwork fixes that slow operations or introduce errors.
Pharmacy Example: A central-fill pharmacy may run multiple dispensing technologies while relying on mail-ready packaging downstream. If those pieces come from different vendors that don’t integrate well together, troubleshooting becomes a guessing game. Your equipment provider should be able to design a cohesive workflow that works within your operation.
3. Industry-Specific Expertise
eCommerce and pharmacy operations have very different requirements. Pharmacies must maintain chain-of-custody, patient safety, and compliance. eCommerce teams battle extreme volume swings, SKU variability, and customer expectations for speed. A knowledgeable partner understands these pressures and designs systems around them.
eCommerce Example: A third-party logistics (3PL) provider shipping thousands of SKUs needs packaging flexibility and fast changeovers. If a vendor doesn’t understand that, you end up with bottlenecks every time a client changes their product mix. A partner with direct fulfillment expertise builds solutions that keep your lines moving even when your inventory shifts hour by hour.
4. Lifecycle Management
Automation systems evolve. Parts wear, processes change, and your facility will almost certainly adapt its workflow over time. Lifecycle management includes preventative maintenance, performance tracking, upgrades, and end-of-life planning. You want a partner who supports you long after go-live.
Pharmacy Example: A specialty pharmacy may add new medication programs or increase patient volume. Without lifecycle planning, the original system becomes a limitation. A partner who monitors performance and suggests upgrades keeps your throughput steady and your accuracy intact.
5. Training and Empowerment
A strong automation partner brings a service team that knows the equipment down to the component level. Their technicians should understand system operation, detailed schematics, fault diagnostics, and the full spare parts strategy. That depth of knowledge keeps your operation moving because problems get resolved quickly and accurately.
eCommerce Example: If a conveyor fault stops your packing line during a high-volume afternoon, you need a service tech who can diagnose the issue within minutes, not hours. A partner with a deeply trained field team can pinpoint root causes, implement fixes that stick, and keep your backlog from spiraling. Their expertise becomes an extension of your operation when it matters most.
6. Hardware, Software, and Material Integration
Your system needs to communicate and operate seamlessly. Integrated software ensures orders flow cleanly from your warehouse management system (WMS), dispensing, or pharmacy systems to packaging. Materials must feed correctly and seal consistently. A provider who understands all three reduces risk and simplifies your operation.
Pharmacy Example: If your mail pharm system prints patient documentation that doesn’t sync with packaging, you risk mis-picks or delays. A partner who integrates data, labeling, and packaging ensures every order moves through the workflow with minimal touches and maximum accuracy.
7. Scalable, Customizable Solutions
Your needs will change. You may add shifts, expand SKUs, shift packaging formats, or retrofit around legacy equipment. A strong partner offers flexible systems that grow with you, whether you’re reconfiguring a single line or scaling to a second facility.
eCommerce Example: A growing retailer may start with one automated bagger, then expand to multiple workcells as volume increases. A partner who designs for modular expansion prevents you from replacing equipment prematurely. They plan for your next three years, not just your first three months.
The Bottom Line
Choosing a packaging and automation provider is a strategic decision. Beyond a basic machinery investment, you’re investing in expertise, support, adaptability, and a relationship that will influence your daily operational performance. The right partner stands beside you through challenges, growth, and continuous improvement.
About Tension Packaging and Automation
Tension Packaging & Automation brings more than 135 years of experience and a service-first mindset to the pharmacy and eCommerce sectors. Here’s how Tension aligns with the qualities above:
- Service-First Approach: Tension provides responsive technical support, trained field technicians, and maintenance programs that prioritize uptime and operational continuity.
- Holistic-Focused Solutions: Tension’s portfolio includes automation equipment, software, packaging materials, labeling, and integrated workflow design, ensuring every component works together.
- Specialized Expertise: Tension understands pharmacy regulations, fulfillment pressures, and the realities of distribution environments. Their solutions reflect real operational needs, not generic assumptions.
- Trained Sales and Support Teams: Tension trains its teams on system operation, troubleshooting, schematics, and spare parts planning. They help customers stay confident and self-sufficient.
- Scalable, Customized Workflow Solutions: Tension excels in deploying flexible systems—new builds, retrofits, and integrated hardware/software/material workflows that evolve with your business.
If you’re ready to explore what a true partnership can look like, connect with Tension’s automation experts today.
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What shippers need to know about the new regional delivery service — and how it may (or may not) fit into their strategy.
Breaking Bottlenecks: How Automation Solutions Improve Your Fulfillment Value Chain from Inbound to Outbound
In the fast-paced, competitive environment eCommerce fulfillment, speed isn’t just an advantage — it’s a necessity.
Yet, many fulfillment centers find themselves facing a frustrating reality: bottlenecks that disrupt the flow at some point from inbound receiving all the way to outbound shipping.
Keeping the fulfillment value chain in balance is critical to long-term success. When operations like picking, packing and shipping aren’t aligned, bottlenecks form — leading to backlogs, overtime and late or missed shipments. If equipment downtime or failure occurs on top of that, the impact can multiply quickly.
The good news? Proactive planning and the right automation solutions help create a connected, resilient system that can absorb disruptions and keep your operation moving efficiently. With the right eCommerce fulfillment solutions, you can eliminate bottlenecks across the entire value chain — increasing throughput, reducing costs and setting your operation up for scalable growth.
Where Bottlenecks Begin — and How to Solve Them
Automation targets bottlenecks where they hurt most — saving time, reducing manual touchpoints and improving consistency.
In many fulfillment centers, a common bottleneck happens at the pack-out stations. As order volumes rise — especially during peak seasons — manual packing teams often struggle to keep pace with the increased picking rates. Even with efficient picking and inventory management upstream, the final packaging step can become a major constraint.
Automated bagging systems help resolve this challenge by increasing the speed and consistency of packing. Solutions like the fitPACK500TM automatically create right-sized bags for each order, eliminating the need for manual packing and reducing the chance of bottlenecks at the end of the line. This not only speeds up order throughput but also helps fulfillment centers avoid the costly cycle of overtime, temporary labor surges and delayed shipments.
Bagging for the Win: Why Right-Sized Packaging Matters
When it comes to improving throughput and cost-efficiency, right-sized packaging solutions like the fitPACK500 make a major impact:
- Speed Gains: The fitPACK500 automatically creates a bag sized perfectly for each order, minimizing waste and maximizing pack-out rates — allowing packaging to catch up with picking speeds.
- Shipping Savings: Smaller, right-sized bags reduce DIM (dimensional weight) surcharges from carriers — a hidden cost many fulfillment centers underestimate.
- Space Efficiency: The fitPACK500’s compact footprint frees up valuable warehouse space compared to bulky carton lines.
- Sustainability: With less void fill and packaging material, right-sized bags help reduce your environmental footprint while also saving costs.
By optimizing packaging as part of your larger fulfillment strategy, you gain speed, efficiency and bottom-line savings all at once.
Future-Proof Your Fulfillment with Smarter Solutions
Bottlenecks are costly — but preventable.
By taking a full-chain view of your warehouse operations, from inbound to outbound, you can identify where automation makes the biggest impact.
Solutions like fitPACK500 for right-sized packaging and tailored eCommerce fulfillment solutions help eliminate bottlenecks, lower shipping costs and set your operation up for long-term success.
Ready to rethink what’s possible in your fulfillment center? Learn more about Tension’s full range of eCommerce fulfillment solutions today. Contact us to get started.
Mastering Multi-Item Orders: How to Eliminate Packaging Headaches in eCommerce Fulfillment
In the fast-paced world of eCommerce fulfillment, efficiency is everything—especially when it comes to packaging. But for many fulfillment centers, shipping orders with multiple products isn’t just time-consuming—it’s a constant source of frustration. Items shift, packages are larger than they need to be to accommodate the items inside, shipping costs climb and the risk of DIM weight surcharges looms large.
If your operation handles bulky, heavy items like jeans or apparel, you know exactly how tricky it can be to keep products secure while creating a package that won’t break the budget. That’s where the fitPACK500TM steps in.
The Problem: Slipping, Shifting and Overspending
Many automated packaging systems are designed for single-SKU orders or lightweight items. When it comes to fulfilling multi-item orders—especially ones that include denser products like jeans—things get complicated:
- Heavy items shift as they move through the automated packaging process, causing jams or poorly sealed packages.
- Pre-sized packaging leads to wasted space, void fill and higher dimensional (DIM) weight surcharges.
- Manual intervention slows down the line, defeating the purpose of automation.
The result? Wasted materials, higher labor costs and frustrated operations teams trying to patch together a fix.
The fitPACK500 Advantage: Built for the Realities of Multi-Item Fulfillment
The fitPACK500 is designed to tackle these challenges head-on—no workarounds required. Here’s how it stands out:
- Adapts to Order Size with Intelligent 3D Scanning: Whether you’re shipping a single pair of jeans or a full outfit, the fitPACK500 uses advanced 3D scanning technology to analyze the order’s exact dimensions in real time and create a perfectly right-sized package. This is especially valuable in robotic picking environments, where order sizes and item combinations vary constantly. No matter the mix or quantity, the fitPACK500 ensures every order gets a package that fits—without manual intervention or guesswork.
- Two-Seal Package = Streamlined Savings: Unlike other systems that require three seals to complete a package, the fitPACK500 uses a dual-seal, pressure-seal module to create a high-quality, secure package with just two seals. That means fewer steps, less wear on components and lower operational costs.
- Stabilizes Heavy or Shifting Items: Our engineering team designed the system with advanced item-guiding technology that keeps even slippery or heavy products stable as they’re packaged.
- Reduces Shipping Costs with Right-Sized Packaging: By creating a package that conforms to the actual dimensions of the order, you eliminate the empty space that leads to costly DIM weight surcharges.
The Payoff: Lower Costs, Better Packages and Happier Customers
With the fitPACK500, fulfillment centers finally have a solution that meets the demands of real-world packaging—not just ideal conditions. Your team saves time, your shipping costs go down and your customers receive compact, quality packages, lending you positive brand recognition.
Curious to see more? Schedule a virtual demo of the fitPACK500 with a member from our team and learn how fitPACK is leading the pack in automated right-sized packaging.
Partner with Tension Packaging & Automation to Innovate, Automate and Outperform with fitPACK500
Your packaging process shouldn’t be the bottleneck in your fulfillment operation. If multi-item orders are slowing you down, costing you more or causing packaging errors, it’s time to level up with a solution designed for complexity.
That’s the fitPACK500 difference. Contact us to start the conversation today.
Tension Showcases the fitPACK500™ at ProMat 2025
March 13, 2025 — KANSAS CITY, Mo., and CHICAGO, Ill. — Tension Packaging & Automation will showcase its comprehensive portfolio of automation systems during ProMat 2025 in Chicago, March 17–20, 2025.
At the premier trade show, which includes the world’s leading manufacturing and supply chain solution providers, Tension will feature the company’s products, the fitPACK500™, HPS300, SLAM, Z-Sort, MAX-PRO 24 and TensionCONNECT™ workflow integration software. These products offer solutions for optimizing packaging and automation while addressing some of the biggest challenges in fulfillment, such as rising labor and shipping costs.
Tension will feature a live look at their innovative fitPACK500, a right-sized packaging system engineered for speed, cost savings and versatility, all within a small footprint. It automatically adjusts package dimensions — length, width and height — and provides a more customized fit without compromising throughput. The Tension team looks forward to showing fitPACK500 at ProMat 2025.
“The fitPACK500 is a versatile and compact system, designed to take the guesswork out of packaging by creating true right-size packages on demand,” said James Herbert, vice president and general manager of Tension Packaging & Automation. “With its small footprint, the fitPACK500 maximizes floor space efficiency while its optimized packaging minimizes shipping costs. Additionally, its intuitive controls make operation seamless, ensuring the best shipping rates and delivering operational efficiencies through its impressive versatility to create custom package lengths, widths and heights.”
ProMat 2025 attendees can experience a live demonstration of the fitPACK500 from Tension’s booth at the exhibition. Advanced reservations for the live demo are encouraged.
In addition, Tension Packaging & Automation Senior Marketing Manager Erin Moloney will also speak at the “Latest & Greatest Advances @ ProMat 2025 in 45 Minutes” ProMat 2025 session on March 17 at 11 a.m. Central, in the MHI Industry Groups Theater. On March 19 at 10:30 a.m. Central, Tension Packaging & Automation Senior National Accounts Manager Herman Kuhlendahl will speak at the “Seamless SLAM Automation: Things You May Not Be Thinking About – Automation that Improves Order Flow from Pick to Ship” in the MHI Industry Groups Theater.
At ProMat 2025, Tension will exhibit in the South Building, booth S3853, at McCormick Place in Chicago, March 17–20, 2025. For more information on ProMat 2025 and how to attend the session “Latest & Greatest Advances @ ProMat 2025 in 45 Minutes,” or the session on “Seamless SLAM Automation: Things You May Not Be Thinking About – Automation that Improves Order Flow From Pick to Ship,” visit https://www.promatshow.com.
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About Tension Packaging & Automation
Tension Packaging & Automation is an industry leader in comprehensive packaging and automation solutions. With a team of dedicated experts, we design, engineer and build scalable automation systems with intuitive, integrated end-to-end software tailored for the pharmacy and eCommerce order fulfillment sectors. As specialists in system integration, we provide extensive expertise across manufacturing, installation, equipment, robotics, software engineering, and ongoing support for both standard and custom automation needs. Learn more at https://tensionautomation.com/.
Tension Packaging & Automation’s parent company, Tension Corporation, was founded in 1886 and is based in Kansas City, Missouri.
New eBook: Warehouse Packaging Automation: From Start to Scale
The eBook Warehouse Packaging Automation: From Start to Scale is a step-by-step guide designed to help eCommerce and pharmacy fulfillment businesses explore, implement, and scale automation effectively. Packed with ROI-driven insights, practical tools, and real-world examples, it simplifies the journey to transforming warehouse operations.
Are you ready to transform your warehouse operations but feel overwhelmed about where to start? Our new eBook, Warehouse Packaging Automation: From Start to Scale, is here to guide you through the process, step-by-step. Designed for companies in eCommerce and pharmacy fulfillment, this comprehensive resource simplifies the journey of exploring, implementing, and scaling automation in your warehouse.
Why Read This eBook?
Understanding and adopting warehouse automation can feel daunting. That’s why we created this guide: to break down the process into manageable steps and provide actionable insights tailored to your business’s unique needs.
Here’s what you’ll gain:
- Clarity: Learn how to assess your current operations and identify when automation makes sense for your organization.
- ROI-Driven Insights: Discover how to align your productivity goals with achievable returns on investment.
- Practical Tools: Access checklists for everything from order flow optimization to integration planning, ensuring your team stays organized and focused.
- Scalability Tips: Get expert advice on starting small and scaling effectively as your operation grows.
- Real-World Examples: Learn from success stories, like how AFA Pharmacy implemented automation tailored to their evolving needs.
A Peek Inside:
The eBook covers key milestones in the automation journey:
- Assess Current Operations – Identify bottlenecks and opportunities for improvement.
- Align Productivity Goals with ROI – Create a roadmap that ensures measurable value.
- Break Down Order Flow – Optimize processes for efficiency and cost-effectiveness.
- Secure Buy-In and Plan Integration – Prepare your team and systems for seamless adoption.
- Go Live and Plan for Long-Term Success – Maintain performance and adapt to future growth.
Who Is This eBook For?
Whether you’re just beginning to explore warehouse automation or are looking to enhance an existing system, this guide is designed to meet you where you are. It’s perfect for operational managers, warehouse directors, and business leaders in industries looking to reduce costs, improve efficiency, and stay competitive.
Ready to Start Your Automation Journey?
Download Warehouse Packaging Automation: From Start to Scale today and take the first step toward transforming your warehouse operations.
Download Now
How fitPACK500 Aligns with Industry Trends for Sustainability, Labor, Fulfillment and Growth
The packaging industry is evolving rapidly, with trends like sustainability, labor shortages, and eCommerce growth reshaping priorities. The fitPACK500TM, a revolutionary rightsized packaging system, empowers businesses to address these challenges with eco-friendly materials, labor-saving automation, and scalable solutions tailored for modern fulfillment needs.
The packaging industry is at a tipping point, where sustainability, labor shortages and e-commerce growth are reshaping the rules of the game. As highlighted in the 2024 PMMI State of the Industry Report, businesses that embrace innovative solutions now will be the ones to lead the pack tomorrow. With challenges come opportunities—and smart automation is the key to staying ahead.
The fitPACK500TM, a revolutionary rightsized packaging system, can help companies stay ahead of these trends.
What Is the fitPACK500?
The fitPACK500, developed by Tension Packaging & Automation, is a revolutionary rightsized packaging system designed for efficiency, cost savings and versatility. It adjusts package dimensions—length, width and height—to fit a variety of product sizes, reducing material waste and optimizing transport space. By creating secure, custom-sized packages, the fitPACK500 helps minimize shipping costs by reducing DIM weight surcharges and optimizing productivity all within a compact footprint. Perfect for fulfillment centers and eCommerce operations, it streamlines packaging processes while cutting costs and enhancing efficiencies.
A More Sustainable Future
The PMMI report highlights a clear shift toward sustainability, with companies prioritizing eco-friendly materials and operational efficiencies to reduce waste.
The fitPACK500 is a game-changer for sustainability initiatives:
- Right-sized Packaging: Minimizes excess material usage, ensuring only the necessary amount is used for every shipment.
- Optimized Transport Space: More compact packages reduce the number of shipments needed.
- Material Flexibility: Compatible with poly material containing post-consumer content (PCR), the fitPACK500 supports your sustainability goals while meeting customer expectations of environmentally responsible business practices.
Addressing Labor Needs with Automation
Labor shortages continue to impact the industry, pushing companies toward automation. The PMMI report underscores how automation is essential for overcoming workforce challenges.
The fitPACK500 addresses these issues by:
- Intuitive HMI: Powered by TensionCONNECT™, it ensures easy operation with minimal training.
- Integration Readiness: Seamlessly connects with third-party systems.
- Cost Reduction: Because fitPACK can accept a variety of product sizes for packaging, it reduces the need for extra staff to operate additional packaging lines needed to accommodate better-fit packaging for various product sizes.
Fulfillment Optimization: Faster, Smarter and Cost-Effective
With DIM weight fees and oversized packaging surcharges on the rise, optimizing fulfillment processes is critical.
The fitPACK500 offers:
- Cost Savings: Rightsized packaging minimizes DIM weight surcharges and optimizes shipping costs.
- Efficiency: Processes up to 20 packages per minute with precision, handling package creation, deflation and labeling seamlessly.
- Error Reduction: Built-in tracking and verification ensure accurate fulfillment, even during peak periods.
Designed for Growth
As eCommerce continues its rapid expansion, businesses need solutions that scale with their operations.
The fitPACK500 grows with your business by:
- Modular Design: Start with a core configuration and add features like recyclable materials handling or return-resealable strips as needed.
- Seamless Integration: Works effortlessly with upstream and downstream equipment, ensuring a streamlined fulfillment process.
- Future-Proof: Adapts to evolving business requirements without requiring costly investments in new machinery.
“Good Things Come in Right-sized Packages”
The trends outlined in the 2024 PMMI State of the Industry Report are shaping the future of packaging. From sustainability to fulfillment optimization, the fitPACK500 is engineered to meet these demands while driving growth and operational efficiency.
As eCommerce expands, fitPACK500 ensures you’re ready to scale and succeed. Curious to see it in action? Request a demo today!
Tail-Wagging Efficiency for Pet & Livestock Pharmacies: Spotlight on Tension’s Automated Fulfillment Solutions for Prescriptions and Supplies
Tension’s automated fulfillment solutions for pet and livestock pharmacies streamline order processing, maximize output, and reduce labor costs, helping to meet the growing demand for pet medications and supplies with seamless system integration and scalable automation.
An estimated 35% of the 57 million U.S. pet owners are Millennials, with 91% viewing “pet parenting” as a key part of their daily lives and regularly seeking veterinary advice for pet care.
With the increasing focus on pet care and well-being, timely access to medications like flea and tick treatments and other essential supplies is more critical than ever. This surge in demand poses challenges for pet pharmacies—whether online, in vet clinics, or hybrid models—to efficiently fulfill orders. Tension Packaging & Automation’s innovative Pet and Livestock Pharmacy Fulfillment Systems meet this need by maximizing output, reducing labor costs, and boosting profitability with streamlined automation solutions.
More Output, Less Labor
Tension’s automated pet and livestock pharmacy fulfillment solutions are engineered to boost prescription output while reducing the labor associated with manual processes. Our comprehensive pharmacy automation equipment, components, and systems streamline essential functions—dispensing, packing, verification, and order delivery—empowering pet and livestock pharmacies to stay competitive and meet patient needs efficiently. By minimizing repetitive tasks for veterinarians and staff, more time is freed for high-value activities such as pet owner consultations and personalized care.
Seamless System Integration, Ease of Use
Whether you’re building a custom pet pharmacy solution or enhancing an existing setup, Tension’s technology adapts to your needs without disrupting ongoing operations. As a systems integrator, we offer a range of automation fulfillment solutions, from standard to custom-manufactured equipment. We take pride in delivering adaptable solutions tailored to meet customer needs, with the flexibility to scale as demands evolve.
- Our proprietary TensionCONNECT™ integration software ensures that all components, including hardware and software, work together seamlessly in an operator-friendly way. Whether integrating new or existing equipment and software, TensionCONNECT orchestrates system communications effortlessly.
- For pet and livestock pharmacies seeking optimized workflow solutions to help streamline fulfillment and prescription verification processes, our innovative PharmaPATH™ back-end pharmacy workflow software solution helps manage prescription workflows through one-task, dedicated workstations, all while integrating seamlessly with front-end pharmacy management systems.
Scalable for Growth in Pet Care Needs
As demand for pet medications grows, your pharmacy’s ability to meet it must keep pace. Tension’s scalable systems adapt to your evolving needs, whether you’re expanding into new markets or managing seasonal demand spikes. With modular designs like the JumpStart system, we ensure your pharmacy stays agile and responsive to pet owners’ needs.
Paw-sitively the Best Solution for Pet & Livestock Pharmacies
Whether your pharmacy focuses on veterinary medications or offers a full range of prescriptions and supplies, Tension’s Pet and Livestock Pharmacy Automation Solutions optimize your operations for maximum efficiency and performance.
Tension’s innovative solutions are built to help your pharmacy grow—without the growing pains. If you’re looking to reduce labor in a way that offers seamless integrations with the flexibility to grow, now’s the time to explore what Tension can offer your pet and livestock pharmacy. For more information on how our systems can transform your operations, contact us today.